Integrated Digitization

FAMOT DIGITAL - CONTINUOUS DIGITIZATION OF THE VALUE CREATION CHAIN

INTERVIEW – CELOS CONNECTIVITY

CONNECTIVITY AS THE PREREQUISITE FOR THE INDUSTRIAL INTERNET

CONNECTIVITY AS THE PREREQUISITE FOR THE INDUSTRIAL INTERNET

It became apparent last year that there is no alternative to digitalization, including for the machine tool manufacturing sector and its customers. We spoke about the next 12 months in an interview with Tommy Kuhn, the Managing Director of DMG MORI Software Solutions GmbH.

Dr. Kuhn, how would you assess 2018?

Digitalization has gained enormously in momentum. 2018 was most certainly felt by many to be the fastest year ever. The discussion about the pros and cons has become more objective when you leave all the hype aside.

Digitalization is understood across the board as a continuous and above all a highly individualised transformation process – with far-reaching interactions beyond the company’s boundaries.

What does that mean exactly?

It means firstly that every company must design and accelerate its digital transformation in a way that is beneficial for its own company and its corporate aims. Digital applications for large companies with hundreds of machines and employees are quite different from applications suitable for small and medium-sized enterprises. But it also means that every company will successively become an interactive part of a collaborative, value-adding network of products, services and data as a result of digitalization – with connectivity acting as the “eligibility to play” for participation in the Industrial Internet.

How does DMG MORI support its customers in the digitalization environment?

Keeping a balance between the traditional and the modern is important for us as a machine tool manufacturer. The name DMG MORI will continue to embody perfect manufacturing equipment in the field of metal cutting and advanced technologies such as 3D printing.

However, our customers can expect the same high quality from us when it comes to holistic and extensive support of their digitalization processes. 

What do you understand by “holistic” and “extensive”?

Firstly, as a bi-directional machine interface our IoTconnector plays a strategic role on the path to the digital era, one whose importance reaches far beyond the shop floor. Where the machine is concerned, we use it to transfer statuses and countless sensor data, analyze these and based on the knowledge gained, progressively optimize the process – already partly adaptively in real-time.

With regard to the interaction between machine and tool, we know in a networked production environment which tools are located where, where tools are needed next and what the actual status of the tool is. This gives the customer all the information he needs for perfect capacity planning and tool logistics. 

Looking beyond the machines and tools, with digital value creation there is an increasing tendency to focus on downstream processes – through to perfect orchestration of people, services and data in a digital factory and beyond into digital value-adding networks.

So there is no networking or connectivity? 

Exactly. Every application level has its own connectivity requirements. Level 1, for example, involves remote support in the event of a service issue. Pictures and video streams are shared and the customer receives the support of an off-site expert quickly. This minimizes downtime.

Level 2 is for integration. In this case, files are shared between software systems and machines – such as the transmission of NC codes from CAM systems to machine controls. This reduces manual set-up times and accelerates process cycles.

Level 3 is for automation. We record basic machine statuses from the control, i. e. the internal workings of the machine, at one-second intervals. Data planning systems, maintenance systems and monitoring solutions alone can significantly boost the utilization of the machine, respond immediately to unscheduled downtimes and create transparency for all manufacturing operations at a central location. Things get significantly more complex in levels 4 and 5. This is where we begin to call up more sensor and job data from the machine every 100 down to 3 milliseconds.

With the corresponding analysis software, this enables a large number of predictions to be made about machine statuses, so the customer can respond to unscheduled downtime even before it happens and thus prevent it, for example, or can measure a tool and adjust it adaptively while a process is running.

What should be the first step towards digitalization?

Important for getting started are a selfcritical analysis of the current status of digital maturity and step-by-step planning with realistic targets. Monitoring of machine performance is generally a good start with high utility because the collected information enables fast optimization of planning and maintenance processes.


FAMOT GRAND OPENING WITH END-TO-END DIGITAL ADDED VALUE

Following an investment of more than 60 million Euros, DMG has expanded and sustainably modernized the traditional Polish plant in Pleszew, which was founded in 1877 and now boasts a total area of 50,000 m². The visitors invited to the Grand Opening ceremony between October 9 to 12, 2018 were shown around the impressive FAMOT digital factory and the new assembly hall, which has capacity for building more than 2,000 machines annually in the CLX, CMX V and CMX U series. 

The FAMOT digital factory is the result of an intensive collaboration between the three DMG MORI subsidiaries ISTOS, DMG MORI Software Solutions and WERKBLiQ. The plant in Poland is impressive proof of the DMG MORI claim to be a customeroriented partner and holistic pioneer of digital transformation. The digital modernization at FAMOT encompasses all levels of the added value chain. Networking with the DMG MORI IT infrastructure with regard to the order management, supply chain and customer relationship functions was a particularly decisive factor. No less challenging was the end-to-end digitization of all internal processes and systems – through to the integration of manual processes, in assembly for example. These two “main topics” were mastered with flying colors. A key element of the successful implementation is the so-called “integration layer” from ISTOS. This open interaction platform enables the integration of different plantspecific applications such as ERP, HR and tool management. It also includes production and machine data acquisition software, central status visualization as well as legacy data management and personnel resource planning. The web-based maintenance platform WERKBLiQ from the DMG MORI subsidiary of the same name also operates via the “integration layer”.

Grand Opening FAMOT 2018

THE ENTIRE DIGITIZATION PROCESS MADE BY DMG MORI

The very heart of the digital transformation at FAMOT, however, is ISTOS PLANNING SOLUTIONS with the modules PRODUCTION PLANNING, PRODUCTION FEEDBACK and PRODUCTION COCKPIT. This productive “triad” enables the end-to-end automation and optimization of all production planning processes, from detailed order scheduling and personnel resource planning right through to the visualization of productionrelevant information in the graphical command station. As a fully integrated production planning and control system with a direct connection to all machines and work stations, ISTOS PLANNING SOLUTIONS enables extended planning and scheduling, direct feedback from the machine or from the work station and the monitoring of machine and process-relevant data in real time. This allows FAMOT to visualize transparently production progress and to respond to changes immediately where necessary. 

The end-to-end digitization of FAMOT together with the expansion of machining – which includes two DMU 600 P machines with double tables and a new XXL assembly hall – create a sound basis for the planned growth. By 2020, plant capacity will include 2,000 of FAMOT’s own machine tools and an additional 2,000 prefabricated machine frames and other components and part sets for another 3,000 machine tools to be produced for various sister companies within the group.


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